Corrugated pre-cured laminate plates for use within wind turbine rotor blades

1. A component for a wind turbine rotor blade, the component comprising:

an assembly of pre-cured laminate plates, each pre-cured laminate plate comprising:

a plate body formed from a combination of fibers and resin, the plate body extending in a thickness direction between a first side and a second side and in a widthwise direction between a first end and a second end, the plate body defining a maximum plate thickness in the thickness direction between the first and second sides; and

a plurality of channels formed in the plate body between the first and second ends, each of the plurality of channels extending in the thickness direction between a top end that is open along the first side of the plate body and a bottom end that terminates at a location between the first and second sides of the plate body such that the plate body defines a reduced thickness between the second side of the plate body and the bottom end of each of the plurality of channels,

wherein a plurality of openings are defined between the bottom end of each of the plurality of channels and the second side of the plate body, each opening of the plurality of openings defining a closed perimeter shape.

2. The component of claim 1 , wherein the reduced thickness is equal to less than about 50% of the maximum plate thickness of the plate body.

3. The component of claim 1 , wherein the fibers are oriented in the plate body along a fiber direction, the plurality of channels extending lengthwise along the plate body in a direction that is parallel to the fiber direction.

4. The component of claim 1 , wherein each of the plurality of channels defines one of a triangular cross-sectional shape, a rectangular cross-sectional shape or a rounded cross-sectional shape.

5. The component of claim 1 , wherein the plurality of openings are spaced apart from one another along a length of each of the plurality of channels.

6. The component of claim 1 , wherein the plurality of channels corresponds to a first plurality of channels, further comprising a second plurality of channels formed in the plate body between the first and second ends, each of the second plurality of channels extending in the thickness direction between a top end that is open along the second side of the plate body and a bottom end that terminates at a location between the first and second sides.

7. The component of claim 6 , wherein the first and second plurality of channels are aligned with one another or spaced apart from one another in the widthwise direction of the plate body.

8. The rotor blade of claim 1 , wherein the first and second plurality of channels are aligned with one another or spaced apart from one another in the widthwise direction of the plate body.

9. A spar cap for a wind turbine rotor blade, the spar cap comprising:

an assembly of pre-cured laminate plates, each pre-cured laminate plate comprising:

a plate body formed from a combination of fibers and resin, the plate body extending in a thickness direction between a first side and a second side and in a widthwise direction between a first end and a second end, the plate body defining a maximum plate thickness in the thickness direction between the first and second sides; and

a plurality of channels formed in the plate body between the first and second ends, each of the plurality of channels extending in the thickness direction between a top end that is open along the first side of the plate body and a bottom end that terminates at a location between the first and second sides of the plate body such that the plate body defines a reduced thickness between the second side of the plate body and the bottom end of each of the plurality of channels,

wherein three or more openings are defined between the bottom end of each of the plurality of channels and the second side of the plate body, the three or more openings being spaced apart from one another along a length of each of the plurality of channels.

10. The spar cap of claim 9 , wherein the reduced thickness is equal to less than about 50% of the maximum plate thickness of the plate body.

11. The spar cap of claim 9 , wherein the fibers are oriented in the plate body along a fiber direction, the plurality of channels extending lengthwise along the plate body in a direction that is parallel to the fiber direction.

12. The spar cap of claim 9 , wherein each of the three or more openings defines a closed perimeter shape.

13. The spar cap of claim 9 , wherein the plurality of channels corresponds to a first plurality of channels, further comprising a second plurality of channels formed in the plate body between the first and second ends, each of the second plurality of channels extending in the thickness direction between a top end that is open along the second side of the plate body and a bottom end that terminates at a location between the first and second sides, the first and second plurality of channels being aligned with one another or being spaced apart from one another in the widthwise direction of the plate body.

14. A rotor blade for a wind turbine, the rotor blade comprising:

a blade root;

a blade tip;

a body shell extending between the blade root and the blade tip; and

a structural component positioned within the body shell, the structural component formed from an assembly of pre-cured laminate plates, each pre-cured laminate plate comprising:

a plate body formed from a combination of fibers and resin, the plate body extending in a thickness direction between a first side and a second side and in a widthwise direction between a first end and a second end, the plate body defining a plate thickness in the thickness direction between the first and second sides; and

a plurality of channels formed in the plate body between the first and second ends, each of the plurality of channels extending in the thickness direction between a top end that is open along the first side of the plate body and a bottom end that terminates at a location between the first and second sides of the plate body such that the plate body defines a reduced thickness between the second side of the plate body and the bottom end of each of the plurality of channels,

wherein three or more openings are defined between the bottom end of each of the plurality of channels and the second side of the plate body, the three or more openings being spaced apart from one another along a length of each of the plurality of channels.

15. The rotor blade of claim 14 , wherein each pre-cured laminate plate conforms to a curvature of the body shell.

16. The rotor blade of claim 14 , wherein the plate thickness corresponds to a maximum thickness of the plate body defined between the first and second sides, wherein the reduced thickness is equal to less than about 50% of the plate thickness of the plate body.

17. The rotor blade of claim 14 , wherein the fibers are oriented in the plate body along a fiber direction, the plurality of channels extending lengthwise along the plate body in a direction that is parallel to the fiber direction.

18. The rotor blade of claim 14 , wherein each of the plurality of channels defines one of a triangular cross-sectional shape, a rectangular cross-sectional shape or a rounded cross-sectional shape.

19. The rotor blade of claim 14 , wherein three or more openings are defined between the bottom end of each of the plurality of channels and the second side of the plate body.

20. The rotor blade of claim 14 , wherein the plurality of channels corresponds to a first plurality of channels, further comprising a second plurality of channels formed in the plate body between the first and second ends, each of the second plurality of channels extending in the thickness direction between a top end that is open along the second side of the plate body and a bottom end that terminates at a location between the first and second sides.